US20120325049A1 - Copper based binder for the fabrication of diamond tools - Google Patents

Copper based binder for the fabrication of diamond tools Download PDF

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Publication number
US20120325049A1
US20120325049A1 US13/582,194 US201113582194A US2012325049A1 US 20120325049 A1 US20120325049 A1 US 20120325049A1 US 201113582194 A US201113582194 A US 201113582194A US 2012325049 A1 US2012325049 A1 US 2012325049A1
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binder
cutting
specific
alloying addition
alloying
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US9156137B2 (en
Inventor
Evgeny Aleksandrovich Levashov
Vladimir Alekseevich Andreev
Viktoriya Vladimirovna Kurbatkina
Alexandr Anatol'evich Zaitsev
Dar'ya Andreevna Sidorenko
Sergei Ivanovich Rupasov
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FEDERAL STATE BUDGETARY INSTITUTION <FEDERAL AGENCY FOR LEGAL PROTECTION OF MILITARY SPECIAL AND DUAL USE INTELLECTUAL ACTIVITY RESULTS> (FSBI <FALPIAR>)
SCIENCE AND TECHNOLOGY "MISIS", National University of
National Univ of Science and Tech
Federal State Budgetary Inst <<Federal Agency for Legal Protection of Military Special
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National Univ of Science and Tech
Federal State Budgetary Inst <<Federal Agency for Legal Protection of Military Special
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Priority claimed from RU2010107315/02A external-priority patent/RU2432249C1/en
Priority claimed from RU2010107314/02A external-priority patent/RU2432247C1/en
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Assigned to NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY "MISIS", FEDERAL STATE BUDGETARY INSTITUTION <FEDERAL AGENCY FOR LEGAL PROTECTION OF MILITARY, SPECIAL AND DUAL USE INTELLECTUAL ACTIVITY RESULTS> (FSBI <FALPIAR>) reassignment NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY "MISIS" ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ANDREEV, VLADIMIR ALEKSEEVICH, KURBATKINA, VIKTORIYA VLADIMIROVNA, LEVASHOV, EVGENY ALEKSANDROVICH, RUPASOV, SERGEI IVANOVICH, SIDORENKO, DAR'YA ANDREEVNA, ZAITSEV, ALEXANDR ANATOL'EVICH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82B—NANOSTRUCTURES FORMED BY MANIPULATION OF INDIVIDUAL ATOMS, MOLECULES, OR LIMITED COLLECTIONS OF ATOMS OR MOLECULES AS DISCRETE UNITS; MANUFACTURE OR TREATMENT THEREOF
    • B82B1/00—Nanostructures formed by manipulation of individual atoms or molecules, or limited collections of atoms or molecules as discrete units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D99/00—Subject matter not provided for in other groups of this subclass
    • B24D99/005—Segments of abrasive wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/05—Metallic powder characterised by the size or surface area of the particles
    • B22F1/054—Nanosized particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
    • B24D3/06—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0425—Copper-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/001—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
    • C22C32/0015—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides with only single oxides as main non-metallic constituents
    • C22C32/0021—Matrix based on noble metals, Cu or alloys thereof
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • C22C32/0052—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only carbides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
    • C22C2026/002—Carbon nanotubes
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes

Definitions

  • This invention relates to powder metallurgy, more specifically, to composite material production methods, and can be used for the production of copper base binders for diamond tools sued in the construction industry and stone working, including different designs of segment cutting-off abrasive wheels used for highway and runway repairs, refurbishment of metallurgical plants and nuclear power plants, renovation of bridges and other structures, as well as drills and segment cutting-off abrasive wheels for cutting of high-strength reinforced concretes.
  • Binder affects the design of a tool. It is the binder that determines the choice of the casing material and the method of bounding the diamond layer with the case. Physical and mechanical properties of binders determine potential shapes and sizes of abrasive diamond tools.
  • a diamond tool binder (RU 2286241 C2, publ. 2006.07.07) comprising a metal selected from the group of iron of the Periodic Table of the Elements, titanium carbide and a metal/metalloid compound. Said binder further comprises zirconium carbide to increase binder strength and diamond grain binding.
  • the prototype of the invention disclosed herein is a diamond tool binder (RU 2172238 C2, publ. 2001.08.20, cl. B24D 3/06) comprising a copper base and tin, nickel, aluminum and ultrafine-grained diamond additives.
  • the object of this invention is to provide diamond tool binders having a higher wear resistance without an essential increase in the required sintering temperature, as well as higher hardness, strength and impact toughness.
  • the copper base diamond tool binder has the following components in the following ratios, wt. %:
  • the alloying addition is introduced in the form of 6-25 m 2 /g specific surface area nanopowder.
  • the alloying addition can be tungsten carbide or tungsten or molybdenum or aluminum oxide or zirconium dioxide or niobium carbide and/or silicon nitride.
  • the copper base diamond tool binder has the following components in the following ratios, wt. %:
  • the alloying addition is introduced in the form of 75-150 m 2 /g specific surface area nanopowder.
  • the alloying addition comprises carbon nanotubes or nanosize grained diamond.
  • the presence of copper, iron, cobalt and strengthening nanoparticles in the binder allows the binder to meet the following requirements:
  • Alloying additives of the composition disclosed above provide for high hardness, high-temperature strength and heat stability of the binders which in turn increase the cutting speed and tool life.
  • alloying additives in quantities below the bottom limit of the range provided herein (1 wt. %) are insufficient for efficient dispersion hardening of the binder, and their effect on the structure and properties of the resultant material is but little.
  • the quantity of the alloying additives is above the top limit of the range provided herein (15 wt. %), the content of the nanosize component is too high.
  • the alloying additives are more refractory and hard and have higher elasticity moduli compare to copper, they concentrate internal stresses thus causing a pronounced brittle behavior of the material, reducing the strength and wear resistance of the binder, increasing the required sintering temperature and compromising the compressibility.
  • alloying additives in quantities below the bottom limit of the range provided herein (0.01 wt. %) are insufficient for efficient dispersion hardening of the binder, and their effect on the structure and properties of the resultant material is but little.
  • the quantity of the alloying additives is above the top limit of the range provided herein (5 wt. %), the content of the nanosize component is too high.
  • the alloying additives are more refractory and hard and have higher elasticity moduli compare to copper, they concentrate internal stresses thus causing a pronounced brittle behavior of the material, reducing the strength and wear resistance of the binder, increasing the required sintering temperature and compromising the compressibility.
  • Binders can be produced using the method of powder metallurgy: sintering followed by compression at the sintering temperature. This method has a high output because the total duration of heating to the sintering temperature, exposure to the sintering temperature, compression and cooling to room temperature is within 15 minutes. High heating rates and a homogeneous temperature distribution in the working chamber are provided by electric current passing through the sintering mould serving also as a die.
  • Exposure to the sintering temperature is immediately followed by compression which produces the required density and shape of the product.
  • the die design allows the process to be conducted in an inert or protective atmosphere to increase the quality of the tool.
  • Tables 1-3 show examples illustrating how the properties of the binder according to the first embodiment of the invention depend on binder composition and the content of the alloying addition.
  • Tables 4-6 show examples illustrating how the properties of the binder according to the second embodiment of the invention depend on binder composition and the content of the alloying addition.
  • the grain size of the alloying additive which can be represented as the specific surface area of the powder has a strong effect on the binder properties.
  • Tables 7-8 show examples illustrating how the properties of the binder depend on the alloying powder specific surface area.
  • the binder materials according to this invention will provide for better economic results compared to counterparts available from the world's leading manufacturers with respect to the price/life and price/output criteria.
  • the diamond segments for cutting highly reinforced concrete are used in an ultrahard abrasive environment.
  • Conventional matrix hardening by tungsten carbide alloying has a concentration limit due to an increase in the required sintering temperature (this reduces the strength of the diamonds and causes extra wear of the process tooling).
  • Using copper as the binder base reduces the raw material costs and allows making the product 15-20% cheaper while retaining its operation merits (tool cutting speed and life) by adding WC, W, Mo and other nanoparticles.
  • Alloying of the materials of the first and second embodiments of the invention provides for high strength, heat conductivity and impact toughness.
  • Controlled low alloying provides for a unique combination of favorable properties e.g. strength, hardness, impact toughness, wear resistance and cutting area friction ratio thus increasing the cutting speed by 30-60% and delivering a tool life under severe loading conditions, e.g. for cutting highly reinforced concrete, by 15-50% longer compared to the conventional material.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Nanotechnology (AREA)
  • Ceramic Engineering (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Powder Metallurgy (AREA)

Abstract

This invention relates to powder metallurgy, more specifically, to composite material production methods, and can be used for the production of copper base binders for diamond tools used in the construction industry and stone working. The copper binder comprises the following components (wt. %): Copper (30-60), iron (20-35), cobalt (10-15), tin (0-10.5), tungsten carbide (0-20) and an alloying addition. According to the first variant the alloying addition is a nanopowder having a specific surface area 6-25 m2/g, which is present in an amount of 1-15% wt. According to the second variant the alloying addition is a nanopowder having a specific surface area of 75-150 m2/g, which is present in an amount of 0.01-5% wt. The binder possesses a high wear resistance without the essential increase in the required sintering temperature, as well as high hardness, strength and impact toughness.

Description

    FIELD OF THE INVENTION
  • This invention relates to powder metallurgy, more specifically, to composite material production methods, and can be used for the production of copper base binders for diamond tools sued in the construction industry and stone working, including different designs of segment cutting-off abrasive wheels used for highway and runway repairs, refurbishment of metallurgical plants and nuclear power plants, renovation of bridges and other structures, as well as drills and segment cutting-off abrasive wheels for cutting of high-strength reinforced concretes.
  • Binder affects the design of a tool. It is the binder that determines the choice of the casing material and the method of bounding the diamond layer with the case. Physical and mechanical properties of binders determine potential shapes and sizes of abrasive diamond tools.
    • BACKGROUND OF THE INVENTION
  • Known is a diamond tool binder (RU 2286241 C2, publ. 2006.07.07) comprising a metal selected from the group of iron of the Periodic Table of the Elements, titanium carbide and a metal/metalloid compound. Said binder further comprises zirconium carbide to increase binder strength and diamond grain binding.
  • Disadvantages of said known binder are the use of expensive and noxious cobalt, a reduced cutting speed for highly reinforced concrete and a shorter tool life.
  • The prototype of the invention disclosed herein is a diamond tool binder (RU 2172238 C2, publ. 2001.08.20, cl. B24D 3/06) comprising a copper base and tin, nickel, aluminum and ultrafine-grained diamond additives.
  • Disadvantages of said material are insufficient wear resistance, hardness, strength and impact toughness.
  • The object of this invention is to provide diamond tool binders having a higher wear resistance without an essential increase in the required sintering temperature, as well as higher hardness, strength and impact toughness.
    • DISCLOSURE OF THE INVENTION
  • Given below are examples pf several types of diamond tool binders according to the invention disclosed herein wherein the above object is achieved by adding a copper group metal as the main binder component and an alloying addition in the form of nanopowder.
  • The copper base diamond tool binder has the following components in the following ratios, wt. %:

  • Cu=30-60

  • Fe=20-35

  • Co=10-15

  • Sn=0-10.5

  • WC=0-20

  • alloying addition=1-15.
  • The alloying addition is introduced in the form of 6-25 m2/g specific surface area nanopowder.
  • In specific embodiments, the alloying addition can be tungsten carbide or tungsten or molybdenum or aluminum oxide or zirconium dioxide or niobium carbide and/or silicon nitride.
  • In another embodiment of this invention, the copper base diamond tool binder has the following components in the following ratios, wt. %:

  • Cu=30-60

  • Fe=20-35

  • Co=10-15

  • Sn=0-10.5

  • WC=0-20

  • alloying addition=0.01-5.
  • The alloying addition is introduced in the form of 75-150 m2/g specific surface area nanopowder.
  • In specific embodiments, the alloying addition comprises carbon nanotubes or nanosize grained diamond.
  • In either embodiment of this invention, the presence of copper, iron, cobalt and strengthening nanoparticles in the binder allows the binder to meet the following requirements:
  • a) good wettability for diamond;
  • b) strong binding of diamond grains;
  • c) self-sharpening, i.e. the binder is worn out as diamond grains are blunting so the blunt grains are chipped out to uncover the cutting faces of new grains;
  • d) sufficient heat stability and high heat conductivity;
  • e) minimum friction ratio to the material being processed;
  • f) linear expansion coefficient close to that of diamond;
  • g) no chemical reaction with the material being processed and the coolant.
  • Alloying additives of the composition disclosed above provide for high hardness, high-temperature strength and heat stability of the binders which in turn increase the cutting speed and tool life.
  • For the first embodiment of this invention, alloying additives in quantities below the bottom limit of the range provided herein (1 wt. %) are insufficient for efficient dispersion hardening of the binder, and their effect on the structure and properties of the resultant material is but little. However, if the quantity of the alloying additives is above the top limit of the range provided herein (15 wt. %), the content of the nanosize component is too high. As the alloying additives are more refractory and hard and have higher elasticity moduli compare to copper, they concentrate internal stresses thus causing a pronounced brittle behavior of the material, reducing the strength and wear resistance of the binder, increasing the required sintering temperature and compromising the compressibility. The above alloying additive concentration range (1-15 wt. %) is only true for 6-25 m2/g specific surface area nanosized powders because theoretical and experimental data suggest that the efficiency of dispersion hardening depends not only on the content of nanoparticles in the alloy but also on their average size which in turn can be calculated from the specific surface area of the nanopowder.
  • For the second embodiment of this invention, alloying additives in quantities below the bottom limit of the range provided herein (0.01 wt. %) are insufficient for efficient dispersion hardening of the binder, and their effect on the structure and properties of the resultant material is but little. However, if the quantity of the alloying additives is above the top limit of the range provided herein (5 wt. %), the content of the nanosize component is too high. As the alloying additives are more refractory and hard and have higher elasticity moduli compare to copper, they concentrate internal stresses thus causing a pronounced brittle behavior of the material, reducing the strength and wear resistance of the binder, increasing the required sintering temperature and compromising the compressibility.
  • The above alloying additive concentration range (0.01-5 wt. %) is only true for 75-150 m2/g specific surface area nanosized powders because theoretical and experimental data suggest that the efficiency of dispersion hardening depends not only on the content of nanoparticles in the alloy but also on their average size which in turn can be calculated from the specific surface area of the nanopowder.
    • EMBODIMENTS OF THE INVENTION
  • Binders can be produced using the method of powder metallurgy: sintering followed by compression at the sintering temperature. This method has a high output because the total duration of heating to the sintering temperature, exposure to the sintering temperature, compression and cooling to room temperature is within 15 minutes. High heating rates and a homogeneous temperature distribution in the working chamber are provided by electric current passing through the sintering mould serving also as a die.
  • Exposure to the sintering temperature is immediately followed by compression which produces the required density and shape of the product. The die design allows the process to be conducted in an inert or protective atmosphere to increase the quality of the tool.
  • Tables 1-3 show examples illustrating how the properties of the binder according to the first embodiment of the invention depend on binder composition and the content of the alloying addition.
  • TABLE 1
    Binder Properties vs Nanosize Grained Tungsten Carbide WC Concentration
    Properties**
    Specific
    Bending Specific cutting Cutting
    Porosity, Rockwell Strength
    Figure US20120325049A1-20121227-P00001
    ,    		 Wear, wheel life, Speed,
    Composition, wt. % % Hardness MPa mm/m2 m2/mm cm2/min
     100% Cubinder* 1 92 690 2.80 0.36 220
    99.1% Cubinder + 0.9% WC 1.1 91 680 2.90 0.30 210
      99% Cubinder + 1% WC 1.5 97 720 2.55 0.39 255
      96% Cubinder + 4% WC 1.5 107 790 1.80 0.55 350
      90% Cubinder + 10% WC 1.6 102 765 2.20 0.45 280
      85% Cubinder + 15% WC 1.8 95 700 2.65 0.38 240
      84% Cubinder + 16% WC 3 87 640 3.50 0.15 150
    *Cubinder composition: 30% Cu; 35% Fe; 15% Co; 10.5% Sn; 9.5% WC
    **specific wear, specific life and cutting speed are given for cutting wheel tests with highly reinforced M400 concrete.
  • TABLE 2
    Binder Properties vs Nanosize Grained Zirconium Oxide Concentration
    Properties**
    Specific
    Bending Specific cutting Cutting
    Porosity, Rockwell Strength
    Figure US20120325049A1-20121227-P00002
    ,    		 Wear, wheel life, Speed,
    Composition, wt. % % Hardness MPa mm/m2 m2/mm cm2/min
     100% Cubinder* 1 93 720 2.50 0.4 230
    99.1% Cubinder + 0.9% ZrO2 1.1 90 680 2.80 0.36 220
      99% Cubinder + 1% ZrO2 1.2 101 745 2.35 0.43 260
      96% Cubinder + 4% ZrO2 1.4 110 850 1.80 0.56 370
      90% Cubinder + 10% ZrO2 1.6 100 810 2.10 0.48 310
      85% Cubinder + 15% ZrO2 1.7 98 780 2.55 0.39 270
      84% Cubinder + 16% ZrO2 3.0 86 650 3.20 0.31 180
    *Cubinder composition: 40% Cu; 25% Fe; 10% Co; 5% Sn; 20% WC
    **specific wear, specific life and cutting speed are given for cutting wheel tests with highly reinforced M400 concrete.
  • TABLE 3
    Binder Properties vs Nanosize Grained Aluminum Oxide Concentration
    Properties**
    Specific
    Bending Specific cutting Cutting
    Porosity, Rockwell Strength
    Figure US20120325049A1-20121227-P00003
    ,     		Wear, wheel life, Speed,
    Composition, wt. % % Hardness MPa mm/m2 m2/mm cm2/min
     100% Cubinder* 1.0 90 650 3.0 0.33 220
    99.1% Cubinder + 0.9% Al2O3 1.1 88 620 3.5 0.29 210
      99% Cubinder + 1% Al2O3 1.2 95 690 2.9 0.34 230
      96% Cubinder + 4% Al2O3 1.4 100 720 2.0 0.50 310
      90% Cubinder + 10% Al2O3 1.7 98 710 2.4 0.42 265
      85% Cubinder + 15% Al2O3 1.8 94 670 2.8 0.36 225
      84% Cubinder + 16% Al2O3 3.0 85 610 3.7 0.27 150
    *Cubinder composition: 60% Cu; 20% Fe; 10% Co; 0% Sn; 10% WC
    **specific wear, specific life and cutting speed are given for cutting wheel tests with highly reinforced M400 concrete.
  • Tables 4-6 show examples illustrating how the properties of the binder according to the second embodiment of the invention depend on binder composition and the content of the alloying addition.
  • TABLE 4
    Binder Properties vs Carbon Nanotube Concentration
    Properties**
    Specific
    Bending Specific cutting Cutting
    Porosity, Rockwell Strength
    Figure US20120325049A1-20121227-P00004
    ,     		Wear, wheel life, Speed,
    Composition, wt. % % Hardness MPa mm/m2 m2/mm cm2/min
      100%
    Figure US20120325049A1-20121227-P00005
    *    		 1 92 690 2.8 0.36 220
    99.994% Cubinder + 0.006% Cnt 1.1 90 690 2.9 0.34 210
     99.99% Cubinder + 0.01% Cnt 1.1 94 730 2.50 0.40 315
     99.95% Cubinder + 0.05% Cnt 1.2 98 750 2.25 0.44 325
       99% Cubinder + 1% Cnt 1.2 103 780 1.90 0.53 340
       95% Cubinder + 5% Cnt 1.6 95 730 2.40 0.42 310
       94% Cubinder + 6% Cnt 3.1 89 620 3.7 0.27 160
    *Cubinder composition: 30% Cu; 35% Fe; 15% Co; 10.5% Sn; 9.5% WC
    **specific wear, specific life and cutting speed are given for cutting wheel tests with highly reinforced M400 concrete.
  • TABLE 5
    Binder Properties vs Carbon Nanotube Concentration
    Properties**
    Specific
    Bending Specific cutting Cutting
    Porosity, Rockwell Strength
    Figure US20120325049A1-20121227-P00006
    ,     		Wear, wheel life, Speed,
    Composition, wt. % % Hardness MPa mm/m2 m2/mm cm2/min
      100%
    Figure US20120325049A1-20121227-P00007
    *    		 1 93 720 2.50 0.40 230
    99.994% Cubinder + 0.006% Cnt 1.1 92 710 2.60 0.38 220
     99.99% Cubinder + 0.01% Cnt 1.1 97 760 2.35 0.43 325
     99.95% Cubinder + 0.05% Cnt 1.2 100 790 2.10 0.48 350
       99% Cubinder + 1% Cnt 1.2 108 820 1.75 0.57 365
       95% Cubinder + 5% Cnt 1.4 98 740 2.25 0.44 315
       94% Cubinder + 6% Cnt 3.0 90 640 3.40 0.29 175
    *Cubinder composition: 40% Cu; 25% Fe; 10% Co; 5% Sn; 20% WC
    **specific wear, specific life and cutting speed are given for cutting wheel tests with highly reinforced M400 concrete.
  • TABLE 6
    Binder Properties vs Nanosize Grained Diamond Concentration
    Properties **
    Specific
    Bending Specific cutting Cutting
    Porosity, Rockwell Strength
    Figure US20120325049A1-20121227-P00008
    ,    		 Wear wheel life, Speed,
    Composition, wt. % % Hardness MPa mm/m2 m2/mm cm2/min
      100%
    Figure US20120325049A1-20121227-P00009
    *    		 1 93 720 2.50 0.40 230
    99.994% Cubinder + 0.006% Cdiamt 1.1 92 710 2.60 0.38 220
     99.99% Cubinder + 0.01% Cdiam 1.1 97 760 2.35 0.43 325
     99.95% Cubinder + 0.05% Cdiam 1.2 100 790 2.10 0.48 350
       99% Cubinder + 1% Cdiam 1.2 108 820 1.75 0.57 365
       95% Cubinder + 5% Cdiam 1.4 98 740 2.25 0.44 315
       94% Cubinder + 6% Cdiam 3.0 90 640 3.40 0.29 175
    *Cubinder composition: 60% Cu; 20% Fe; 10% Co; 0% Sn; 10% WC
    **specific wear, specific life and cutting speed are given for cutting wheel tests with highly reinforced M400 concrete.
  • Along with the binder composition, the grain size of the alloying additive which can be represented as the specific surface area of the powder has a strong effect on the binder properties. Tables 7-8 show examples illustrating how the properties of the binder depend on the alloying powder specific surface area.
  • TABLE 7
    Binder Properties for the First Embodiment of the Invention vs Nanosize Grained Tungsten
    Carbide WC Powder Specific Surface Area
    Properties**
    Specific
    WC Specific Bending Specific cutting wheel Cutting
    Surface Area, Porosity, Rockwell Strength
    Figure US20120325049A1-20121227-P00010
    ,     		Wear, life, Speed,
    m2/g % Hardness MPa mm/m2 m2/mm cm2/min
    100% Cubinder* 1 92 690 2.8 0.36 220
     5 1.2 91 650 3.2 0.30 200
     6 1.5 102 730 2.65 0.43 250
    10 1.8 109 790 1.80 0.55 350
    20 2.0 104 750 2.10 0.48 320
    25 2.1 94 710 2.50 0.40 225
    27 4.5 80 390 4.60 0.18 170
    *Cubinder composition: 30% Cu; 35% Fe; 15% Co; 10.5% Sn; 9.5% WC
    **specific wear, specific life and cutting speed are given for cutting wheel tests with highly reinforced M400 concrete.
  • TABLE 8
    Binder Properties vs Alloying Additive Specific Surface Area*
    Propertes**
    Specific
    Carbon Nanotube Bending Specific cutting wheel Cutting
    Specific Surface Porosity, Rockwell Strength
    Figure US20120325049A1-20121227-P00011
    ,    		 Wear, life, Speed,
    Area, m2/g % Hardness MPa mm/m2 m2/mm cm2/min
    100% Cubinder* 1 92 690 2.80 0.36 220
    70 1.1 90 690 2.90 0.34 210
    75 1.1 94 720 2.55 0.39 300
    100 1.2 100 760 2.15 0.47 325
    125 1.4 103 780 1.90 0.53 340
    150 1.6 95 730 2.45 0.41 315
    160 2.3 90 660 3.4 0.29 200
    *Cubinder composition: 30% Cu; 35% Fe; 15% Co; 10.5% Sn; 9.5% WC
    **specific wear, specific life and cutting speed are given for cutting wheel tests with highly reinforced M400 concrete.
  • The binder materials according to this invention will provide for better economic results compared to counterparts available from the world's leading manufacturers with respect to the price/life and price/output criteria. For example, the diamond segments for cutting highly reinforced concrete are used in an ultrahard abrasive environment. Conventional matrix hardening by tungsten carbide alloying has a concentration limit due to an increase in the required sintering temperature (this reduces the strength of the diamonds and causes extra wear of the process tooling).
  • Using copper as the binder base reduces the raw material costs and allows making the product 15-20% cheaper while retaining its operation merits (tool cutting speed and life) by adding WC, W, Mo and other nanoparticles.
  • Alloying of the materials of the first and second embodiments of the invention provides for high strength, heat conductivity and impact toughness. Controlled low alloying provides for a unique combination of favorable properties e.g. strength, hardness, impact toughness, wear resistance and cutting area friction ratio thus increasing the cutting speed by 30-60% and delivering a tool life under severe loading conditions, e.g. for cutting highly reinforced concrete, by 15-50% longer compared to the conventional material.

Claims (4)

1. Copper based binder for the fabrication of diamond tools comprising 6-25 m2/g specific surface area nanopowder alloying addition with the following component ratios, wt. %:

Cu=30-60

Fe=20-35

Co=10-15

Sn=0-10.5

WC=0-20

alloying addition=1-15.
2. Binder of claim 1 wherein said alloying addition is tungsten carbide or tungsten or molybdenum or aluminum oxide or zirconium dioxide or niobium carbide and/or silicon nitride.
3. Copper based binder for the fabrication of diamond tools comprising 75-150 m2/g specific surface area nanopowder alloying addition with the following component ratios, wt. %:

Cu=30-60

Fe=20-35

Co=10-15

Sn=0-10.5

WC=0-20

alloying addition=0.01-5.
4. Binder of claim 1 wherein said alloying addition is in the form of carbon nanotupes of nanosize grained diamond.
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